Dunnage conversion machine, method, and product with a polygonal cross-section

Abstract

A machine for converting a sheet material into a relatively less dense dunnage product includes a forming assembly and a feeding assembly downstream of the forming assembly. The forming assembly is configured to form the sheet material into a tubular shape with lateral edges of the sheet material adjacent one another. A deflector at a downstream end of the forming assembly is configured to engage the lateral edges of the sheet material and to urge the lateral edges into an interior of the tubular shape. This juxtaposes lateral edge portions of the sheet material adjacent the respective lateral edges. A forming channel at a downstream end of the forming assembly faces the deflector to receive the lateral edge portions and shape them into a tab. Finally, the feeding assembly includes rotating connecting members that engage and connect the overlapping lateral edge portions of the sheet material forming the tab.

The invention claimed is: 
     
       1. A machine for converting a sheet stock material into a relatively less dense dunnage product as the sheet stock material moves in a downstream direction through the machine, the machine comprising:
 a forming assembly that defines a portion of a path for the sheet stock material through the machine in the downstream direction, the forming assembly being configured to form the sheet stock material into a tubular shape with lateral edges of the sheet stock material adjacent one another; 
 the forming assembly including an external former having curved side surfaces that define a converging chute and an internal former mounted to extend telescopically into the external former, spaced from interior side surfaces of the external former, the external former and the internal former cooperating to define a path for the sheet stock material between the external former and the internal former; 
 external former including an inwardly-extending deflector that protrudes from an internal surface toward a downstream end of the external former that is configured to engage the lateral edges of the sheet stock material and to urge the lateral edges inward into an interior of the tubular shape with lateral edge portions of the sheet stock material adjacent the lateral edges being brought into juxtaposition, and an opening opposite the deflector; 
 the internal former including a recess that defines a forming channel at a downstream end of the forming assembly facing the deflector for receiving the lateral edge portions from the deflector and shaping them into a tab; 
 a feeding assembly downstream of the forming assembly, the feeding assembly including rotating connecting members that engage and connect the overlapping lateral edge portions of the sheet stock material forming the tab; and 
 the internal former including an opening in a surface and a roller accessible from the opening in the surface of the internal former that cooperates with a pivotally mounted roller pivotally moveable into engagement with the roller through the opening in the external former for passage of the pivotally mounted roller therethrough, the pivotally mounted roller being driven by a motor to advance the sheet stock material therebetween to facilitate loading the sheet stock material through the forming assembly. 
 
     
     
       2. The machine according to  claim 1 , where the forming assembly and the feeding assembly are configured to urge portions of the sheet stock material respectively adjacent opposite sides of the tab toward the tab for passage between the rotating connecting members along with the tab such that the adjacent portions are connected to the tab and form with the tab a ridge on one side of the tubular shape. 
     
     
       3. The machine according to  claim 1 , where at least one of (a) the deflector and the forming channel are coextensive, (b) the deflector extends into the forming channel, and (c) the deflector and the forming channel extend in a downstream direction. 
     
     
       4. The machine according to  claim 1 , further comprising a severing assembly downstream of the feeding assembly that includes a pair of rollers configured to engage the sheet stock material therebetween and to rotate the rollers at a faster speed than the feeding assembly to tear the sheet stock material at a line of perforation.